KTM F9399U8 Owner'S Manual Download

Page: 70 / 177

12 SERVICE WORK ON THE CHASSIS

12.22

Removing the air filter

Note

Engine damage

Unfiltered intake air has a negative effect on the service life of the engine.

Dust and dirt will enter the engine without an air filter.

–

Only operate the vehicle if it is equipped with an air filter.

Note

Environmental hazard

Hazardous substances cause environmental damage.

–

Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Preparatory work

–

Remove the seat. (

p. 67)

A00742-10

Main work

–

Remove screws

–

Remove air filter cover

A00743-10

–

Remove air filter

12.23

Cleaning the air filter and air filter box

Note

Environmental hazard

Hazardous substances cause environmental damage.

–

Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

Preparatory work

–

Remove the seat. (

p. 67)

–

Remove the air filter.

(

p. 68)

Summary of Contents for F9399U8

Page 1: ...OWNER S MANUAL 2021 450 RALLY Factory Replica Art no 3214230en...

Page 2: ......

Page 3: ...ns prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop produc tion of a particular mo...

Page 4: ...button 20 6 16 Idle speed adjusting screw 20 6 17 Shift lever 21 6 18 Foot brake lever 21 6 19 Side stand 21 6 20 Steering lock 22 6 21 Locking the steering 22 6 22 Unlocking the steering 22 7 COMBIN...

Page 5: ...Adjusting the steering head bearing play 62 12 13 Greasing the steering head bearing 64 12 14 Removing the shock absorber 64 12 15 Installing the shock absorber 65 12 16 Removing front fender 66 12 1...

Page 6: ...6 Changing the coolant 116 17 TUNING THE ENGINE 118 17 1 Checking the play in the throttle cable 118 17 2 Adjusting the play in the throttle cable 118 17 3 Adjusting the idle speed 119 17 4 Checking...

Page 7: ...TABLE OF CONTENTS 5 30 3 Green and blue symbols 171 INDEX 172...

Page 8: ...ned experts using the special tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a tes...

Page 9: ...eferred to at the relevant passages Info Various information and warning labels are attached in prominent locations on the product described Do not remove any information or warning labels If they are...

Page 10: ...m may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed s...

Page 11: ...rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regulations of the respective country Because motorcycles are not subject...

Page 12: ...3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner...

Page 13: ...VIEW OF VEHICLE 4 11 4 1 View of vehicle front left A00454 10 1 Clutch lever p 15 2 Seat release strap 3 Side stand p 21 4 Shift lever p 21...

Page 14: ...vehicle rear right side A00455 10 1 Fuel pump switch p 17 2 Stop button p 15 2 Light switch p 16 2 Turn signal switch p 16 2 Horn button p 16 3 Start button p 16 4 Combination instrument 5 Throttle g...

Page 15: ...ring head on the right 5 2 Type label A00441 10 The type label 1 is located on the steering head on the left 5 3 Engine number 401949 10 The engine number 1 is stamped on the left side of the engine u...

Page 16: ...number 401947 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber article number H03307 10 The shock absorber article number 1 is located on the left side of the...

Page 17: ...r operates the front brake 6 3 Throttle grip L03002 10 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Stop button A00447 10 The stop button 1 is fitted on the left side of the ha...

Page 18: ...handle bar Possible states Turn signal off Turn signal switch is in the central position Turn signal left on Turn signal switch turned to the left Turn signal right on Turn signal switch turned to the...

Page 19: ...hed on Right fuel level warning lamp lights up orange The fuel level of the rear fuel tank has reached the reserve mark The coolant temperature warning lamp lights up red The coolant temperature is to...

Page 20: ...he engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning D...

Page 21: ...er caps 1 2 and 3 counterclockwise and lift off 6 14 Closing fuel tank filler caps A00736 11 Mount fuel tank filler caps 1 2 and 3 and turn clock wise until the fuel tanks are tightly closed Info Rout...

Page 22: ...art button has returned to its basic position Possible states The cold start button is activated The cold start button is pushed in all the way The cold start button is deactivated The cold start butt...

Page 23: ...ons can be seen in the photograph The neutral or idle position is between the first and second gears 6 18 Foot brake lever 401956 10 Foot brake lever 1 is located in front of the right footrest The re...

Page 24: ...icle on a firm and level surface 400732 01 Park the vehicle Turn handlebar as far as possible to the right Insert the key for the steering lock into the steering lock turn it to the left press it in a...

Page 25: ...heel size After the display function check the wheel circumference WS is displayed briefly Info The number 2205 equals the circumference of the 21 front wheel with standard tires The display then chan...

Page 26: ...ttom right of the display Press the button for 2 3 seconds The Setup menu is displayed and the active functions are shown Info If no button is pressed for 10 12 seconds the settings are automatically...

Page 27: ...ted for 15 20 seconds or there is no signal from the wheel speed sensor then the settings are automatically stored and the Setup menu is closed 7 6 Viewing the lap time Info This function can only be...

Page 28: ...ce hours of the motor are displayed The service hour counter stores the total traveling time Info The service hour counter is necessary for ensuring that service work is carried out at the right inter...

Page 29: ...changes to H or ODO 7 10 Adjusting the unit of measurement 400329 01 Condition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display Press...

Page 30: ...until CLK appears at the bottom right of the display Press the button for 2 3 seconds Press the but ton for 2 3 seconds Increases the value Briefly press the button Increases the value Press the but...

Page 31: ...P appears at the bottom right of the display Briefly press the button Press the but ton for 2 3 seconds The stop watch and the lap time are reset Briefly press the button Select a lap from 1 10 Press...

Page 32: ...ction Briefly press the button No function 7 17 Display mode SPEED TR2 trip master 2 400324 01 Repeatedly press the button briefly until TR2 appears at the top right of the display TR2 trip master 2 r...

Page 33: ...the average speed calculated using TR1 trip master 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last im...

Page 34: ...speed sensor and ends 3 seconds after the last impulse Press the but ton for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the but ton for 2...

Page 35: ...on Activates Mph display Changes to the next dis play changes from selec tion to the Setup menu Stores and closes the Setup menu Display mode SPEED CLK time The display changes to the Setup menu of th...

Page 36: ...age speed 2 No function Next display mode No function No function Display mode SPEED S1 stop watch 1 Displays of TR1 A1 and S1 are reset to 0 0 Next display mode No function No function Display mode S...

Page 37: ...t your riding speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents...

Page 38: ...ootrests when riding If you carry luggage make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels Info Mo...

Page 39: ...ire pressure p 106 Check the spoke tension p 107 Clean the dust boots of the fork legs p 56 Bleed the fork legs p 55 Check the air filter Check the fuel filter Check the settings of all controls and e...

Page 40: ...t change into a low gear at high engine speed Info If unusual noises occur while riding stop immediately switch off the engine and contact an authorized KTM workshop First gear is used for starting of...

Page 41: ...ate to your road speed Use the braking effect of the engine on long downhill stretches Change down one or two gears but do not over rev the engine You will have to apply the brakes far less frequently...

Page 42: ...e Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before cover...

Page 43: ...ficient This will result in problems with the fuel system Refuel only with clean fuel that meets the specified standards Your authorized KTM workshop will be glad to help Note Environmental hazard Imp...

Page 44: ...gs p 98 Check brake discs p 90 Check the brake lines for damage and tightness Check rear brake fluid level p 96 Check the free travel of the foot brake lever p 95 Check the frame and the link fork Che...

Page 45: ...the fault memory after the test ride using the KTM diagnostics tool Make a service entry in KTM Dealer net One time interval Periodic interval 10 3 Recommended work every 48 months every 12 months af...

Page 46: ...ange the valves valve springs and valve spring seats Check the camshaft and rocker arm Change the connecting rod con rod bearing and crank pin Change the radial shaft seal rings of the water pump and...

Page 47: ...es high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed compression adjuster has an effect for exam...

Page 48: ...rber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop wil...

Page 49: ...by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 24 clicks Standard 20 clicks Sport 16 clicks Info Turn clockwise to increase damping turn counterclo...

Page 50: ...Checking riding sag of the shock absorber Condition The fuel tanks are half full 400990 10 Measure dimension A of rear wheel unloaded p 47 With another person holding the motorcycle the rider wear in...

Page 51: ...70 Remove the shock absorber p 64 After removing the shock absorber clean it thoroughly F02386 10 Main work Loosen screw 1 Turn adjusting ring 2 until the spring is no longer under ten sion Hook wrenc...

Page 52: ...mm 274 lb in Weight of rider 65 75 kg 143 165 lb 51 N mm 291 lb in Weight of rider 75 85 kg 165 187 lb 54 N mm 308 lb in Weight of rider 85 95 kg 187 209 lb 57 N mm 325 lb in Weight of rider 95 kg 209...

Page 53: ...pression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior A00451 10 Turn adjusting screws 1 clockwise all the way Info Adjusting screws 1 are located...

Page 54: ...licks Info Turn clockwise to increase the damping turn counter clockwise to reduce damping when the shock absorber rebounds Mount protection caps 1 11 14 Handlebar position F02396 10 The holes on the...

Page 55: ...lamping bars 6 Remove screws 7 Take off handlebar supports 8 with coni cal rubber pieces 9 Place handlebar supports 8 with conical rubber pieces 9 in the desired position Mount and tighten screws 7 Gu...

Page 56: ...NING THE CHASSIS 54 Info The elastomers are available in different versions Mount screws 1 and tighten evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the installed gaps are...

Page 57: ...parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove motorcycle from the lift stand Remove lift stand To park the motorcycle press side stand 1 to th...

Page 58: ...dents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and oil the dust boo...

Page 59: ...t and tighten screws 2 Position fork protector on left fork leg Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 7 Removing fork legs Preparatory work Raise the mot...

Page 60: ...op triple clamp M8 15 Nm 11 1 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 17 Nm 12 5 lbf ft A00467 11 Position brake caliper Mount and tighten screws 4 Guideline Screw front brake c...

Page 61: ...rs Fix handlebar 4 onto the instrument support with cable tie s 5 Remove screws 6 and take off steering damper 7 A00475 10 Secure lower triple clamp 8 against falling out Remove screw 9 Remove screw b...

Page 62: ...eering head seal 1 is correctly posi tioned Slide on protective ring 2 and O ring 3 F02400 10 Position the upper triple clamp Mount screw 4 but do not tighten yet F02401 10 Position the fork legs Blee...

Page 63: ...5 Nm 11 1 lbf ft F02433 10 Position steering damper and mount and tighten screws bl Guideline Screw steering damper M6 15 Nm 11 1 lbf ft Remove the cable ties and position the handlebar Position the h...

Page 64: ...tectable on the steering head bearing If there is detectable play Adjust the steering head bearing play p 62 Move the handlebar to and fro over the entire steering range It must be possible to move th...

Page 65: ...5 Guideline Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243 F02433 11 Position steering damper 3 and mount and tighten screws 2 Guideline Screw steering damper M6 15 Nm 11 1 lbf ft Remove th...

Page 66: ...clamp p 60 12 14 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 55 Fold out the side stand and secure it Remove the seat p 67 Remove main silencer p 70 F02403 10...

Page 67: ...refully position shock absorber into the vehicle from above L03054 10 Mount and tighten screw 1 with the washer Guideline Fitting shock absorber top M10 60 Nm 44 3 lbf ft Loctite 243 L03055 10 Mount a...

Page 68: ...m 18 4 lbf ft Finishing work Install the main silencer p 70 Mount the seat p 67 Remove motorcycle from the lift stand p 55 12 16 Removing front fender A00480 10 Remove screws 1 and take off fender 2 1...

Page 69: ...ks Insert locking pin 1 into the lock housing and push down the rear of the seat until the locking pin engages with a click Check that the seat is correctly mounted 12 20 Removing the activated carbon...

Page 70: ...fluid etc correctly and in compliance with the applicable regulations Preparatory work Remove the seat p 67 A00742 10 Main work Remove screws 1 Remove air filter cover 2 A00743 10 Remove air filter 3...

Page 71: ...p 166 Clean the air filter box Check intake flange for damage and looseness Finishing work Install the air filter p 69 Mount the seat p 67 12 24 Installing the air filter A00743 11 Main work Mount cle...

Page 72: ...ncer Mount screw 1 but do not tighten yet Attach springs 2 Spring hook 50305017000C1 Tighten screw 1 Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 12 27 Changing the glass fiber yarn filling...

Page 73: ...ger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off th...

Page 74: ...2016100 F02404 10 Clean quick release coupling 3 thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconn...

Page 75: ...low fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes...

Page 76: ...should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Spray silicone spray onto a lint free cleaning cloth and lightly lubricate the O ring of the quick release coupling...

Page 77: ...lint free cleaning cloth and lightly lubricate the O ring of the quick release coupling Silicone spray p 166 Join quick release coupling 3 Position the fuel line in the holder Finishing work Install t...

Page 78: ...ing 1 thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the quick release coupling Info Remaini...

Page 79: ...cs free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning...

Page 80: ...sure chain tension A Info Top chain section 1 must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 7 mm If the chain tension does...

Page 81: ...ters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spin dle M25x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters enables different second...

Page 82: ...m 10 71 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains we...

Page 83: ...the chain guide for wear Info Wear can be seen on the front of the chain guide If the chain guide is worn Change the chain guide Check that the chain guide is firmly seated If the chain guide is loose...

Page 84: ...ng Preparatory work Remove the seat p 67 Remove the engine guard p 88 Remove side cover p 86 Remove front right fuel tank p 73 A00753 10 Main work Check the throttle cable routing Both throttle cables...

Page 85: ...ing 12 43 Checking correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective...

Page 86: ...ake off cover 4 with membrane 5 Check fluid level Fluid level A below con tainer rim 4 mm 0 16 in If the level of the fluid does not meet specifications Correct the fluid level of the hydraulic clutch...

Page 87: ...eyes If brake fluid spills on to your clothing change the clothing Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake f...

Page 88: ...ithout bubbles Occasionally extract the fluid from the master cylinder reser voir to prevent overflowing Remove bleeding syringe 8 Mount and tighten bleeder screw 9 Join plug in connector 6 Join quick...

Page 89: ...nnectors 1 of the turn signals Remove screws 2 A00746 10 Remove screws 3 Unlock quick releases 4 Carefully push the side cover to the rear and remove 12 46 Mounting side cover A00746 11 Position side...

Page 90: ...urn signals 12 47 Removing front fairing A00750 10 Unlock quick releases 1 Raise the front fairing tilt forward and take off 12 48 Mounting front fairing A00750 10 Position front fairing Lock quick re...

Page 91: ...SERVICE WORK ON THE CHASSIS 12 89 12 50 Installing the engine guard A00749 10 Position the engine guard Mount and tighten screws 1 Guideline Screw engine guard M8 25 Nm 18 4 lbf ft...

Page 92: ...adjustments while riding 13 2 Checking brake discs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Your authori...

Page 93: ...accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the MIN marking the brake system is leaking or the brake linings are worn down Chec...

Page 94: ...1 Take off cover 2 with membrane 3 Add brake fluid to level A Guideline Dimension A 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 164 Position cover 2 with membrane 3 Mount and tighten screws 1 Info Immedia...

Page 95: ...ghly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake flu...

Page 96: ...the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Take off cover 2 with membrane 3 F02416 10 Manually press the brake caliper toward the brake disc to push b...

Page 97: ...e travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake syste...

Page 98: ...ake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the...

Page 99: ...act with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear...

Page 100: ...e the brake system to fail Ensure that service work and repairs are performed professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritatio...

Page 101: ...al damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purp...

Page 102: ...ert new brake linings 8 insert pin 4 and mount cotter pin F02419 10 Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Co...

Page 103: ...Loosen screws 3 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold front wheel and remove wheel s...

Page 104: ...linings are correctly positioned Mount and tighten screw 3 Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Info Ensure that the grip of the wheel spindle does not con tact with the righ...

Page 105: ...to be pushed forward Push the rear wheel forward as far as possible Remove chain from rear sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake d...

Page 106: ...he spacers of the rear sprocket carrier Long life grease p 166 Insert rear sprocket carrier 2 into the rear hub F02421 10 Position rear wheel and insert wheel spindle 3 The brake linings are correctly...

Page 107: ...S03055 10 Lay the rear wheel on a workbench with the rear sprocket fac ing upward and insert the wheel spindle in the hub To check the play A hold the rear wheel tight and try to rotate the rear sproc...

Page 108: ...he week of manufacture and the last two digits the year of manu facture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are mor...

Page 109: ...and in particular on a new vehicle Your authorized KTM workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke...

Page 110: ...art of the charge 9 V Dispose of 12 V batteries with less than the minimum voltage correctly Preparatory work Remove the seat p 67 A00747 10 Main work Pull fuel vapor valve 1 off the holder and hang i...

Page 111: ...nvironmental hazard 12 V batteries contain environmentally hazardous materials Do not dispose of 12 V batteries as household waste Dispose of 12 V batteries at a collection point for used batteries In...

Page 112: ...the battery charger after charging and disconnect from the 12 V battery Connect the negative cable to the 12 V battery Finishing work Mount the seat p 67 15 4 Changing main fuse Warning Fire hazard I...

Page 113: ...that the electrical system is functioning properly Tip Insert a spare fuse so that it is available if needed Mount the protection caps A00747 10 Pull fuel vapor valve 1 off the holder and hang it to t...

Page 114: ...g tail light Fuse 7 10 A radiator fan Fuse 8 10 A front fuel pump rear fuel pump diagnos tics EFI lambda sensor heater map switch malfunction indicator lamp fuel vapor valve Info A faulty fuse has a b...

Page 115: ...to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger...

Page 116: ...with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your...

Page 117: ...coolant Mount and tighten screw 1 with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 16 5 Refilling with coolant Warning Danger of poisoning Coolant is toxic and a health hazard...

Page 118: ...skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly wi...

Page 119: ...COOLING SYSTEM 16 117 Finishing work Install the engine guard p 89...

Page 120: ...s and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let...

Page 121: ...Check the throttle grip for smooth operation Finishing work Install the front right fuel tank p 75 Install the engine guard p 89 Mount side cover p 87 Mount the seat p 67 Check the play in the throttl...

Page 122: ...boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 120 17 5 Adjusting the basic position of the shift lever 401950 12 Remove screw...

Page 123: ...ilter cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding ri...

Page 124: ...O rings Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft S03043 10 Position oil screen 4 with the O rings on a pin wrench Position the pin wrench through the drill hole of the screw plug in...

Page 125: ...000 Allow the engine oil to drain completely Thoroughly clean the parts and the sealing surface Insert the new oil filter S03040 10 Lubricate the O ring of the oil filter cover and mount it with oil f...

Page 126: ...il Total filling level oil change Engine oil 1 40 l 1 48 qt Engine oil SAE 10W 50 p 164 Total filling level engine service with oil radiator Engine oil 1 80 l 1 9 qt Engine oil SAE 10W 50 p 164 Info T...

Page 127: ...0W 50 p 164 Info For optimal performance of the engine oil do not mix different types of engine oil We recommend making an oil change in this case Install and tighten the oil filler plug with O ring D...

Page 128: ...the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts with a normal commercial motor cycle clea...

Page 129: ...s operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 126 Clean brake system Info After EVERY trip on sa...

Page 130: ...ements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling f...

Page 131: ...Because the engine will not warm up sufficiently the water vapor produced during combustion will condense caus ing engine parts and the exhaust system to rust 20 2 Preparing for use after storage 401...

Page 132: ...g gap Guideline Spark plug electrode gap 0 9 mm 0 035 in Faulty ignition system Check the ignition system Short circuit cable in wiring harness frayed stop button faulty Check the wiring harness visua...

Page 133: ...de Check cabling for damage and electri cal plug in connections for corrosion and damage Read out fault memory using the KTM diagnostics tool High oil consumption Engine vent hose bent Route the vent...

Page 134: ...OTING 132 Faults Possible cause Action The high beam low beam position light tail light license plate lamp and horn are not working Fuse 6 is blown Change the fuses of individual electri cal power con...

Page 135: ...Blink code FI warning lamp MIL 12 FI warning lamp MIL flashes 1x long 2x briefly Error level condition Coolant temperature sensor input signal too low Coolant temperature sensor input signal too high...

Page 136: ...BLINK CODE 134 Blink code FI warning lamp MIL 41 FI warning lamp MIL flashes 4x long 1x briefly Error level condition Fuel pump relay short circuit to ground or open circuit Open short circuit to plu...

Page 137: ...n bearing No bearing bush DLC coated piston pin Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 trochoidal pump...

Page 138: ...243 Nut water pump impeller M6 6 Nm 4 4 lbf ft Loctite 243 Screw alternator cover M6 10 Nm 7 4 lbf ft Screw bearing bolt torque limiter M6 10 Nm 7 4 lbf ft Loctite 243 Screw camshaft retaining bracket...

Page 139: ...Screw cylinder head M10x1 25 1st stage 10 Nm 7 4 lbf ft 2nd stage 30 Nm 22 1 lbf ft 3rd stage 50 Nm 36 9 lbf ft Collar and thread oiled Nut rotor M12x1 60 Nm 44 3 lbf ft Thread oiled with engine oil c...

Page 140: ...lybdenum steel tubes powder coated Suspension travel front 305 mm 12 01 in rear 300 mm 11 81 in Brake system Disc brakes floating brake calipers Brake discs diameter front 300 mm 11 81 in rear 240 mm...

Page 141: ...ense plate lamp LED 23 6 Tires Front tire Rear tire 90 90 21 M C 54S M S TT Continental TKC 80 140 80 18 M C 70R M S TT Continental TKC 80 The tires specified represent one of the possible series prod...

Page 142: ...g Comfort 45 clicks Standard 40 clicks Sport 30 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 16 clicks Spring preload Standard 11 mm Spring rate Weight of rider 65 kg 143 lb 48 N...

Page 143: ...arter motor M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw connection foot brake cylin der M6 10 Nm 7 4 lbf ft Loctite 243 Screw conn...

Page 144: ...lbf ft Loctite 243 Screw steering stem bottom M8 20 Nm 14 8 lbf ft Loctite 243 Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Screw top triple clamp M8 15 Nm 11 1 lbf ft Fitting engine moun...

Page 145: ...TECHNICAL DATA 23 143...

Page 146: ...24 WIRING DIAGRAM 144 24 1 Page 1 of 10 A00759 01...

Page 147: ...WIRING DIAGRAM 24 145 Components M10 Electric starter system K10 Starter relay with main fuse G10 12 V battery C10 Capacitor T20 Voltage regulator G20 Alternator K30 Power relay...

Page 148: ...24 WIRING DIAGRAM 146 24 2 Page 2 of 10 A00760 01...

Page 149: ...WIRING DIAGRAM 24 147 Components F7 Fuse R10 Diode M14 Radiator fan B33 Temperature switch F6 Fuse R11 Diode K13 High beam relay K14 Low beam relay...

Page 150: ...24 WIRING DIAGRAM 148 24 3 Page 3 of 10 A00761 01...

Page 151: ...WIRING DIAGRAM 24 149 Components F8 Fuse K41 Relay for rear fuel pump M12 Rear fuel pump K40 Relay for front fuel pump M13 Front fuel pump...

Page 152: ...24 WIRING DIAGRAM 150 24 4 Page 4 of 10 A00762 01...

Page 153: ...WIRING DIAGRAM 24 151 Components A11 EFI control unit R30 CAN bus terminating resistor M51 Injection valve M20 Fuel vapor valve B51 Lambda sensor...

Page 154: ...24 WIRING DIAGRAM 152 24 5 Page 5 of 10 A00763 01...

Page 155: ...I control unit B21 Coolant temperature sensor R51 Ignition coil B37 Crankshaft speed sensor B34 Shift shaft sensor B43 Throttle valve position sensor B26 Tilt sensor B41 Induction manifold pressure se...

Page 156: ...24 WIRING DIAGRAM 154 24 6 Page 6 of 10 A00764 01...

Page 157: ...WIRING DIAGRAM 24 155 Components F1 Fuse F2 Fuse F3 Fuse F4 Fuse F5 Fuse B77 Rear brake light switch P36 Brake tail light B35 Oil pressure sensor...

Page 158: ...24 WIRING DIAGRAM 156 24 7 Page 7 of 10 A00765 01...

Page 159: ...WIRING DIAGRAM 24 157 Components P20 Rear fuel level warning lamp P24 Front fuel level warning lamp S56 Fuel pump switch S21 Electric starter button P31 Malfunction indicator lamp...

Page 160: ...24 WIRING DIAGRAM 158 24 8 Page 8 of 10 A00766 01...

Page 161: ...ts P26 Indicator lamp for coolant temperature P27 Oil pressure warning lamp B76 Crankshaft speed sensor P23 Induction manifold pressure sensor S29 Light switch horn button stop button E11 Low beam E12...

Page 162: ...24 WIRING DIAGRAM 160 24 9 Page 9 of 10 A00767 01...

Page 163: ...WIRING DIAGRAM 24 161 Components P15 Horn...

Page 164: ...24 WIRING DIAGRAM 162 24 10 Page 10 of 10 A00768 01...

Page 165: ...ignal indicator lamp P42 Right front turn signal P41 Left front turn signal P46 Right rear turn signal P45 Left rear turn signal E60 License plate lamp Cable colors bl Black br Brown bu Blue gn Green...

Page 166: ...Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must...

Page 167: ...n SAE p 168 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 Standard cl...

Page 168: ...grease Recommended supplier MOTOREX Bike Grease 2000 Off road chain spray Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Pr...

Page 169: ...AUXILIARY SUBSTANCES 26 167 Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic...

Page 170: ...ce intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated wit...

Page 171: ...INDEX OF SPECIAL TERMS 28 169 OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics...

Page 172: ...29 LIST OF ABBREVIATIONS 170 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 173: ...engine 30 2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention Active driving aids are also represented by yellow or orange symbols Left...

Page 174: ...in checking 79 cleaning 77 Chain guide checking 79 Chain tension adjusting 78 checking 78 Cleaning 126 127 Clutch fluid level checking correcting 83 fluid changing 85 Clutch lever 15 basic position ad...

Page 175: ...119 Idle speed adjusting screw 20 Implied warranty 10 Intended use 7 K Key number 13 L Light switch 16 Link fork checking 82 Lower triple clamp installing 60 removing 58 Low speed compression damping...

Page 176: ...sing 64 Steering head bearing play adjusting 62 checking 62 Steering lock 22 Stop button 15 Storage 128 129 T Technical data capacities 137 chassis 138 chassis tightening torques 141 electrical system...

Page 177: ...3214230en 3214230en 09 2020 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM...

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KTM F9399U8, Owner'S Manual

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